Alkylation and transalkylation processes using a hydrated catalyst

ABSTRACT

A composition useful for catalyzing alkylation and transalkylation reactions comprises a molecular sieve having alkylation and/or transalkylation activity, an inorganic refractory oxide component and greater than 3.5 weight percent water. Such a catalyst has been found to maintain a long life when used to produce ethylbenzene in an integrated process in which benzene is alkylated with ethylene and transalkylated with diethylbenzene. The catalyst can also be used to produce cumene via an integrated process in which benzene is alkylated with propylene and transalkylated with diisopropylbenzene.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.07/729,458, filed in the U.S. Patent and Trademark Office on Jul. 12,1991 now U.S. Pat. No. 5,240,889.

BACKGROUND OF THE INVENTION

This invention relates to alkylation and transalkylation processes andcatalysts for use therein. The invention is particularly concerned withcatalysts having an initial content of water sufficiently high todecrease catalyst deactivation by inhibiting reactant decompositionduring the start-up of such processes, thereby significantly increasingthe life of the catalysts.

In the past it has been common practice to alkylate aromatic moleculessuch as benzene, toluene and xylene with ethylene, propylene and otherolefins using acidic homogeneous Friedel-Crafts type catalysts such asaluminum halides or heterogeneous acidic silica-alumina catalysts. Suchprocesses have several disadvantages including corrosion problem causedby some of the catalysts and difficulty in controlling the productdistribution obtained from the alkylation reactions. Often, the desiredproduct is the monoalkylate rather than the di- or trialkylate. In aneffort to avoid a large production of di- and trialkylate products andto extend catalyst life, it is conventional practice to use a largeexcess of the aromatic compound.

To avoid some of the problems associated with earlier commercialalkylation processes, solid zeolite-containing catalysts have been usedin recent years to promote the alkylation of aromatic compounds witholefins and other alkylating agents, especially the alkylation ofbenzene with ethylene. Such zeolite-containing catalysts are normallyprepared by combining a zeolite with a refractory oxide binder orprecursor thereof, mulling and extruding the mixture, drying theextrudates and then calcining the dried extrudates at high temperaturesto provide the extrudates with the strength required to withstandcommercial operations. Naturally occurring and synthetic zeolitestypically contain a relatively large concentration of sodium ions andare therefore not catalytically active. Thus, before a zeolite is mixedwith the refractory oxide component or precursor thereof in themanufacturing of a zeolite-based catalyst, the zeolite is normallysubjected to ion exchange, typically with ammonium ions, to reduce itssodium concentration as low as practically possible and increase itscatalytic activity. However, since ammonia is known to poison the acidsites of the zeolite, it is common practice to carry out the calcinationof the dried extrudates at such temperatures that substantially all ofthe ammonium ions in the catalyst are decomposed into hydrogen ions andammonia which is driven out of the catalyst as a gas. The use of suchcalcination temperatures also drives off substantially all of the waterpresent and typically results in a substantially dry catalyst.

Normally, zeolite-based alkylation catalysts prepared as described aboveare used in fixed bed reactors through which the reactants arecontinuously passed. Although such fixed bed processes usingzeolite-containing catalysts have advantages over earlier commercialprocesses, the life and deactivation rate of the catalysts, especiallywhen used to produce ethylbenzene by reacting ethylene with benzene,have been observed in pilot plant studies to vary from one catalyst toanother with the life of some of the catalysts being so low thatcommercial processes using such catalysts would be uneconomical.

Accordingly, there is a need for zeolite-containing catalysts that donot readily deactivate when used to catalyze alkylation andtransalkylation reactions, and therefore consistently maintain arelatively long life.

SUMMARY OF THE INVENTION

In accordance with the invention, it has now been surprisingly foundthat the life of catalysts comprising an inorganic refractory oxidecomponent and a crystalline molecular sieve in alkylation andtransalkylation processes is dependent on the water content of thecatalyst. It has been further found, contrary to what is commonlybelieved in the art, that it is most desirable to maintain a minimumlevel of water in such catalysts during process start-up to avoidsubstantial decomposition of the first reactant introduced into thealkylation or transalkylation reactor as the temperature in the reactionzone is increased to alkylation and/or transalkylation temperatures. Ithas been found that this minimum level is typically equal to or greaterthan the equilibrium amount of water the catalyst would contain at anytemperature during the start-up procedure that is greater than thetemperature at which the first introduced reactant begins to decompose.Normally, this minimum level of water is greater than 3.5 weight percentof the catalyst and generally ranges between about 4.0 and 25 weightpercent. Accordingly, the invention is directed to a catalystcomposition of long life which, in its broadest embodiment, contains amolecular sieve and at least about 3.5 weight percent water based on thetotal weight of the catalyst. Preferably, the molecular sieve used inpreparing the catalyst is a steam-stabilized, modified Y zeolite. Thelevel of water in the catalyst typically ranges between about 4.0 and 25weight percent, preferably between about 5.0 and about 15 weightpercent. All water contents referred to herein are calculated bymeasuring weight loss on ignition (LOI), which is normally determined bycalculating the weight loss after heating at 1000° C. for two hours, andthen subtracting the amount of weight loss due to ammonium iondecomposition into ammonia.

The catalyst of the invention is typically prepared by exchanging amolecular sieve with ammonium ions, mixing the resultant ion-exchangedsieve with a porous, inorganic refractory oxide component or precursorthereof, extruding the resultant mixture to form extrudates, drying theextrudates, calcining the dried extrudates, and then hydrating thecalcined extrudates so they contain water in amounts above the minimumlevel of 3.5 weight percent. As used herein, "extruding" includes allforms of pelleting including tableting, extruding, prilling and thelike. Alternatively, if it is desired to use the catalyst in a fluidizedbed reactor, a slurry of the ammonium-exchanged molecular sieve andrefractory oxide component can be prepared, spray-dried to produceparticles which typically range between 40 and 80 microns in diameterand then hydrated to the desired water content.

Catalysts of the invention have been found to resist deactivation duringprocess start up and thereby possess relatively long lives when used ina variety of alkylation and transalkylation processes in which anorganic feedstock is contacted with an organic reactant to form analkylated organic compound in the presence of such catalysts. In onespecific embodiment of the process of the invention, the catalyst of theinvention is employed in the alkylation zone of a process for producingethylbenzene via the alkylation of benzene with ethylene and may also beemployed downstream in the process in a transalkylation zone whereinbenzene is subjected to transalkylation by contacting it withdiethylbenzene, an undesired by-product of the reaction between benzeneand ethylene, to produce additional quantities of ethylbenzene. The useof a long-life catalyst of the invention in such a process cansubstantially reduce capital investment and operating costs by enablingless catalyst to be used in smaller alkylation and transalkylationreactors, and decreasing the number of times the catalyst must beregenerated.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 in the drawing is a schematic flow diagram of a process forproducing cumene or ethylbenzene utilizing both alkylation andtransalkylation reactors containing the catalyst of the invention; and

FIG. 2 is a plot which shows the position in beds of the catalyst of theinvention and a catalyst containing less than the minimum requiredamount of water of the maximum or peak temperature for the reaction ofbenzene with ethylene to produce ethylbenzene versus days on stream.

DETAILED DESCRIPTION OF THE INVENTION

The molecular sieve-containing catalyst of the invention, which istypically free of hydrogenation metal components, comprises acrystalline zeolitic or nonzeolitic molecular sieve composited with aporous, inorganic refractory oxide matrix or binder. The term "molecularsieve" as used herein refers to any material capable of separating atomsor molecules based on their dimensions. The term "nonzeolitic" as usedherein refers to molecular sieves whose frameworks are not formed ofsubstantially only silicon and aluminum atoms in tetrahedralcoordination with oxygen atoms whereas the term "zeolitic" as usedherein refers to molecular sieves whose frameworks are formed ofsubstantially only silicon and aluminum atoms in tetrahedralcoordination with oxygen atoms, such as the framework present in ZSM-5type zeolites, Y zeolites, and X zeolites. Examples of nonzeolitic,crystalline molecular sieves which may serve as the active alkylation ortransalkylation component of the catalyst includesilicoaluminophosphates, metalloaluminophosphates, titanium silicates,galliosilicates, ferrosilicates, chromosilicates, borosilicates,pillared clays, delaminated clays and crystalline silicas such assilicalite. Several of these nonzeolitic molecular sieves are discussedin more detail in U.S. Pat. Nos. 4,867,861 and 4,829,040, thedisclosures of which are hereby incorporated by reference in theirentireties. Examples of zeolitic, crystalline molecular sieves which maybe used as the active alkylation or transalkylation component of thecatalyst include those selected from the group of Y zeolites, fluoridedY zeolites, X zeolites, zeolite beta, zeolite L, zeolite omega,mordenite and modifications of such zeolites. It is preferred that thecrystalline molecular sieve used in the catalyst of the invention have aConstraint Index below about 1.0 and pores defined by 12-membered ringsof oxygen atoms, i.e., a pore size greater than 7.0 angstroms.

The preferred molecular sieves for use in the catalyst of the inventionare Y zeolites and modified Y zeolites. U.S. Pat. No. 3,130,007, thedisclosure of which is hereby incorporated by reference in its entirety,describes Y-type zeolites having an overall silica-to-alumina mole ratiobetween about 3.0 and about 6.0, with a typical Y zeolite having anoverall silica-to-alumina mole ratio of about 5.0.

The modified Y zeolites suitable for use in preparing the catalyst ofthe invention are generally derived from Y zeolites by treatment whichresults in a significant modification of the Y zeolite frameworkstructure and composition, usually an increase in the frameworksilica-to-alumina mole ratio to a value typically above 6.0, and/or areduction in unit cell size. It will be understood, however, that, inconverting a Y zeolite starting material to a modified Y zeolite usefulin the present invention, the resulting modified Y zeolite may not haveexactly the same X-ray powder diffraction pattern for Y zeolites as isdisclosed in U.S. Pat. No. 3,130,007. The d-spacings may be shiftedsomewhat due to a shrinkage in the unit cell size caused by an increasein the framework silica-to-alumina mole ratio. The essential crystalstructure of the Y zeolite will, however, be retained so that theessential X-ray powder diffraction pattern of the modified zeolite usedin the catalyst will be consistent with that of either Y zeolite itselfor a Y zeolite of reduced unit cell size. Examples of modified Yzeolites that can be used in preparing the catalyst of the inventioninclude steam-stabilized Y zeolites, dealuminated Y zeolites andultrahydrophobic Y zeolites.

Steam-stabilized Y zeolites are Y zeolites which have beenhydrothermally treated to increase their framework silica-to-aluminamole ratio with only a small increase in their overall silica-to-aluminamole ratio. Steam stabilization normally involves calcination of theammonium or hydrogen form of the Y zeolite starting material atrelatively high temperatures, typically above about 900° F., in thepresence of steam. This treatment results in the expulsion oftetrahedral aluminum from framework into nonframework positions, butnormally does not remove the aluminum from the zeolite and thereforedoes not significantly increase the overall silica-to-alumina mole ratioof the starting Y zeolite.

A preferred steam-stabilized Y zeolite for use as the starting molecularsieve in preparing the catalyst of the invention is one produced by (1)ammonium exchanging a Y zeolite to a sodium content between about 0.6and 5 weight percent, calculated as Na₂ O, (2) calcining theammonium-exchanged zeolite at a temperature between about 600° F. and1650° F. in the presence of steam at a water vapor partial pressure ofat least 0.2 p.s.i.a., preferably above about 2.0 p.s.i.a., and mostpreferably between about 5.0 and 15 p.s.i.a., to reduce the unit cellsize of the ammonium-exchanged zeolite to a value in the range betweenabout 24.35 and about 24.65 angstroms, preferably between about 24.40and 24.64 angstroms, and then (3) ammonium exchanging the steam-calcinedzeolite to replace at least 25 percent of the residual sodium ions andobtain a zeolite product containing less than about 1.0 weight percentsodium, preferably less than about 0.6 weight percent sodium, and mostpreferably below about 0.2 weight percent sodium, calculated as Na₂ O.Such a Y zeolite is highly stable and maintains a high activity. Thezeolite is described in detail in U.S. Pat. No. 3,929,672, thedisclosure of which is hereby incorporated by reference in its entirety.

The preferred steam-stabilized Y zeolites, whether produced by theprocess described above or steam stabilized via a different route, have(1) a unit cell size or dimension a_(o) greater than about 24.45angstroms, preferably between about 24.46 and 24.61 angstroms, and mostpreferably between about 24.52 and 24.59 angstroms and (2) a sorptivecapacity for water vapor greater than about 15 weight percent at 25° C.and a p/p° value of 0.10, preferably greater than 18 weight percent, andusually between about 18 and 25 weight percent. As used herein, "p/p°"represent the water vapor partial pressure to which the zeolite isexposed divided by the water vapor partial pressure at 25° C. Theoverall silica-to-alumina mole ratio of these modified Y zeolitesgenerally ranges between 5.0 and 6.0, typically between about 5.4 and5.9. Examples of preferred steam-stabilized Y zeolites include LZY-82 orY-82 zeolite and LZY-84 or Y-84 zeolite sold by UOP, CP300-56 zeolitesold by the PQ Corporation, and CBV-530 and CBV-531 zeolites sold byConteka-BV.

The dealuminated Y zeolites that can be used as the starting molecularsieve for preparing the catalyst are Y zeolites which have beenchemically treated with acids, salts, or chelating agents to increasetheir overall silica-to-alumina mole ratio. The preferred dealuminated Yzeolites are prepared by dealuminating Y zeolites having an overallsilica-to-alumina mole ratio below about 6.0 and are described in detailin U.S. Pat. Nos. 4,503,023 and 4,711,770, the disclosures of whichpatents are hereby incorporated by reference in their entireties. Apreferred group of such zeolites is known as LZ-210 zeolites, zeoliticaluminosilicate molecular sieves available from UOP. LZ-210 zeolites andother zeolites are conveniently prepared from a Y zeolite startingmaterial in overall silica-to-alumina mole ratios between about 6.0 andabout 20, although higher ratios are possible. Preferred LZ-210 zeoliteshave an overall silica-to-alumina mole ratio of about 6.1 to about 16.Typically, the unit cell size is at or below 24.65 angstroms and willnormally range between about 24.40 and about 24.60 angstroms. LZ-210zeolites having an overall silica-to-alumina mole ratio below 20generally have a sorptive capacity for water vapor of at least 20 weightpercent based on the anhydrous weight of the zeolite at 25° C. and 4.6millimeters mercury water vapor partial pressure. Normally, the oxygensorptive capacity at 100 millimeters mercury and -183° C. will be atleast 25 weight percent. In general, LZ-210 zeolites are prepared bytreating Y zeolites with an aqueous solution of a fluorosilicate salt,preferably a solution of ammonium hexafluorosilicate.

Ultrahydrophobic zeolites which can be used as a component of thecatalyst of the invention are modified Y zeolites having a unit cellsize between about 24.20 and about 24.45 angstroms, preferably betweenabout 24.20 and 24.39 angstroms, most preferably between about 24.20 and24.35 angstroms, and a sorptive capacity for water vapor less than about5 weight percent, preferably less than about 4 weight percent, of thezeolite at 25° C. and a p/p° value of 0.10. The zeolites are the same orsimilar to the UHP-Y zeolites disclosed in U.S. Pat. No. 4,401,556 andU.K. Patent 2,014,970 published on Jun. 29, 1982, the disclosures ofwhich patents are hereby incorporated by reference in their entireties.According to these references, a UHP-Y zeolite is defined as a zeolitehaving a silica-to-alumina mole ratio of from 4.5 to 35, the essentialX-ray powder diffraction pattern of zeolite Y, an ion exchange capacityof not greater than 0.070, a unit cell size from 24.20 to 24.45angstroms, a surface area of at least 350 square meters per gram (BET),a sorptive capacity for water vapor less than 5 weight percent at 25° C.and a p/p° value of 0.10, and a Residual Butanol Test Value of not morethan 0.4 weight percent. The Residual Butanol Test is a measure of theadsorptive selectivity of zeolite adsorbents for relatively nonpolarorganic molecules under conditions in which there is active competitionbetween water and less polar molecules for adsorption on the zeolite.The test procedure is described in detail in the above-identifiedpatents.

Preferably, the ultrahydrophobic zeolite has a silica-to-alumina moleratio between about 4.5 and 9, the essential X-ray powder diffractionpattern of zeolite Y, an ion exchange capacity of not greater than0.070, and a Residual Butanol Test Value of not more than 0.4 weightpercent. More preferably, the ultrahydrophobic zeolite is LZ-10 zeolite,a modified Y zeolite having a silica-to-alumina mole ratio between about4.5 and about 6.0, a surface area between about 500 and 700 squaremeters per gram, a unit cell size between about 24.20 and 24.35angstroms, and a sorptive capacity for water vapor less than about 5percent by weight of the zeolite at 25° C. and a p/p° value of 0.10.

Before the molecular sieve to be utilized in the catalyst of theinvention is combined with the porous, inorganic refractory oxide whichwill serve as the binder or matrix for the sieve, it will normally becatalytically active for alkylation and transalkylation reactions andcontain ammonium ions. The activity of the molecular sieve is typicallydependent on the amount of alkali metal associated with the acid sitesof the sieve. Some of the molecular sieves that are suitable for use inthe catalyst, such as the steam-stabilized Y zeolites described above,will already contain ammonium ions and have such a low concentration ofsodium or other alkali metal cations that they will possess therequisite activity and can be combined directly with the refractoryoxide component. If, however, the molecular sieve contains a highconcentration of sodium or other alkali metal cations, it is normallydesirable to exchange the sieve with ammonium ions to lower the alkalimetal content and provide the sieve with ammonium ions.

The ammonium ion exchange is carried out by mixing the molecular sievewith an aqueous solution containing a dissolved ammonium salt, such asammonium nitrate, ammonium sulfate, ammonium chloride and the like. Theresulting slurry is stirred for between about 1 and about 5 hours attemperatures above ambient but less than 100° C. If sodium levels below0.50 weight percent are desired, the ion exchange procedure willnormally have to be repeated at least once. Typically, the ion exchangeprocedure will be repeated at least twice and occasionally several timesto reduce the sodium or other alkali metal content preferably to below0.2 weight percent, calculated as Na₂ O.

The molecular sieve possessing alkylation and/or transalkylationactivity is combined with one or more inorganic refractory oxidecomponents, or precursors thereof, such as alumina, silica, titania,magnesia, zirconia, beryllia, a naturally occurring clay, such askaolin, hectorite, sepiolite, attapulgite, montmorillonite orbeidellite, silica-alumina, silica-magnesia, silica-titania, mixturesthereof and other such combinations and the like. Examples of precursorsthat may be used include peptized alumina, alumina gel, hydratedalumina, silica-alumina hydrogels and silica sols. The inorganicrefractory oxide components or precursors thereof, which serve as amatrix for the molecular sieve, are typically amorphous and are usuallymixed or comulled with the molecular sieve in amounts such that thefinal catalyst mixture will comprise (1) between about 50 and about 95weight percent molecular sieve, preferably between about 70 and 95weight percent, and (2) between about 5 and 50 weight percent of one ormore inorganic refractory oxides, preferably between about 5 and 30weight percent.

The desired inorganic refractory oxide component(s) or precursor(s)thereof is typically mulled, normally in the form of a powder, with theammonium-exchanged molecular sieve particles. After mulling, the mixtureis extruded through a die having openings of a cross sectional size andshape desired in the final catalyst particles. The catalyst may be madein any shape extrudates including, among others, extrudates having thecross section of a circle or a three-leaf clover similar to the shapeshown in FIGS. 8 and 8A of U.S. Pat. No. 4,028,227, the disclosure ofwhich is hereby incorporated by reference in its entirety. Normally, thelength of the catalyst particles ranges between about 0.10 and 0.50 inchand the diameter between about 0.03 and 0.08 inch. The preferred sizesof the catalyst particles are described in detail in U.S. Pat. No.4,185,040, the disclosure of which is hereby incorporated by referencein its entirety. After the extruded catalyst has been broken intoparticles of the desired length, the catalyst particles are dried andsubjected to calcination at an elevated temperature, normally betweenabout 600° F. and about 1600° F., preferably between about 700° F. andabout 1200° F., to produce a catalyst of high crushing strength.

It has typically been the practice in the art of making molecularsieve-containing catalysts of any type to carry out the finalcalcination step at temperatures that are sufficiently high to not onlyprovide the high crushing strength required of the catalyst but also todecompose substantially all of the ammonium ions in the molecular sieveinto ammonia and hydrogen ions, thereby activating the catalyst byremoving ammonia which neutralizes the active acid sites in themolecular sieve. The use of these high calcination temperatures alsodrives off substantially all of the water present and typically resultsin a substantially dry catalyst. It has now been surprisingly found thatthe life of an alkylation or transalkylation catalyst prepared asdescribed above is decreased when the catalyst is substantially dry. Inorder to maintain a relatively long catalyst life, it has been foundthat the water content of the fresh catalyst must be above about 3.5weight percent before it is used in alkylation and/or transalkylationprocesses.

In view of the above and in accordance with the invention, the calcinedcatalyst particles are hydrated so they contain water in an amount aboveabout 3.5 weight percent. Typically, the hydration is carried out suchthat the hydrated catalyst particles will contain greater than about 4.0weight percent water, preferably more than about 5.0 weight percent,more preferably greater than about 6.0 weight percent, and mostpreferably greater than about 7.0 weight percent. Typically, the amountof water in the catalyst will range between about 4.0 and about 25weight percent, preferably between about 5.0 and about 15 weightpercent, and more preferably between about 5.0 and 10 weight percent.

As mentioned previously, the discovery that the water level in amolecular sieve-based alkylation or transalkylation catalystbeneficially affects the life of the catalyst is quite surprising inlight of the conventional practice of driving off substantially all ofthe water during calcination. Although the invention is not limited toany theory of operation, it is believed that this surprising phenomenonis due to the extra water preferentially adsorbing onto some of theactive sites in the molecular sieve and thereby deactivating them sothey do not crack, during process start-up, the molecules of thereactant which undergoes alkylation or transalkylation once processstart-up is completed. During start-up, this reactant is introduced intothe alkylation or transalkylation reaction zone in contact with thecatalyst, and the temperature in the reaction zone is slowly increasedto reaction temperature before the alkylating or transalkylating agentis introduced. During this initial heat-up period, the water content ofthe catalyst is determined by the equilibrium between the catalyst, thereactant first introduced into the reaction zone, and the amount ofwater in the reaction zone, if any, at temperatures in the reactionzone. If the catalyst contains less than its equilibrium amount of waterat any time during the initial heat-up, it is believed the more activesites in the molecular sieve tend to promote cracking of the moleculesof the first introduced reactant into materials that react with benzeneor condense to form larger molecules which deposit on the catalyst,thereby poisoning active sites and decreasing catalyst life. It isbelieved that the presence of water in excess of equilibrium amounts atany temperature during the heat-up step that is above the temperature atwhich the first introduced reactant undergoes cracking will deactivatecracking sites in the catalyst and thereby decrease the formation duringstart-up of larger molecules which poison the catalyst and therebysignificantly reduce its life.

In order to accomplish hydration of the catalyst particles so theycontain the desired amount of water, the calcined particles may besprayed with water. Normally, this procedure is carried out by passingthe calcined catalyst particles on a moving belt under a series of sprayor fog nozzles designed to finely disperse the water. The molecularsieve portion of the catalyst is highly hydrophilic and will quicklyabsorb the water. The level of hydration is controlled by adjusting therate at which the catalyst passes under the nozzles or the rate of waterflow through the nozzles. Usually, the temperature during the hydrationstep is maintained between about 5° C. and about 100° C. The watercontent of the catalyst is calculated by measuring weight loss onignition (LOI), which is normally determined by calculating the weightloss after heating for 2 hours at 1000° C., and then subtracting theamount of weight loss due to ammonium ion decomposition into ammonia.Since a catalyst containing water in excess of the desired amount, i.e.,greater than the equilibrium amount of water the catalyst will containat any time during process start-up, will lose that water onceequilibrium is established during start-up, the hydration step can becarried out to give the catalyst any amount of water as long as it isequal to or exceeds the equilibrium amount.

As is discussed in U.S. Pat. No. 5,036,033, which patent is herebyincorporated by reference in its entirety, it has been found that aminimum concentration of at least 250 ppmw ammonium ions, calculated as(NH₄)₂ O on a volatiles-free basis, in molecular sieve-based alkylationand transalkylation catalysts helps to maintain high levels ofselectivity for desired products. Thus, the catalyst of the inventionwill typically contain, in addition to greater than 3.5 weight percentwater, more than this minimum amount of ammonium ions, preferablybetween about 2,000 and 8,000 ppmw. The desired ammonium ionconcentration in the catalyst is achieved by controlling the time andtemperature conditions at which the extruded catalyst particles arecalcined. In some cases, calcination at lower temperatures will providenot only the desired crush strength and ammonium ion concentration, butwill also leave the required amount of water in the catalyst and therebymake it unnecessary to carry out a separate hydration step. Thus,"hydrating" and "hydration" as used herein not only mean a separate stepin which water is added to the catalyst after calcination but alsoencompass a calcination step carried out under conditions such that thedesired amount of water remains on the catalyst particles.

The hydration procedure described above is part of the actual process ofmaking the catalyst of the invention at the manufacturing plant. It willbe understood, however, that procedures other than that described abovecan be used to hydrate the catalyst either in the manufacturing plant atthe time the catalyst is made or at some other time at the manufacturingplant or elsewhere. For example, the extruded catalyst particles can behydrated in-situ in the alkylation or transalkylation reactor by passinga water-containing gas, such as humid air, or a water-containingreactant, such as wet liquid benzene, over the catalyst at relativelylow temperatures until the catalyst contains the desired amount ofwater. Also, the catalyst particles can be stored at the manufacturingplant or elsewhere so that they are in contact with the surrounding airuntil the desired amount of water has been absorbed.

Catalysts prepared as described above are useful in a wide variety ofalkylation and transalkylation processes in which an alkylated organiccompound is produced by contacting an organic feedstock with an organicreactant in the presence of the catalyst. Alkylation can be broadlydefined as the addition or insertion of an alkyl group into a molecule.Thus, alkylation reactions are diverse in nature. In transalkylationreactions, which are closely related to alkylation reactions, an alkylgroup moves from one molecule to another. The catalyst of the inventionis effective in catalyzing both alkylation and transalkylation reactionswhile maintaining a relatively long life.

In general, the catalyst of the invention can be used to catalyze thealkylation of saturated and unsaturated, branched and straight chain,aliphatic compounds, monocyclic and polycyclic aromatic compounds andsubstituted derivatives of such monocyclic and polycyclic compounds, andcycloaliphatic compounds. The alkylating agent used may be any compoundcapable of reacting with the compound to be alkylated. Typicalalkylating agents include alkenes or olefins, alcohols such as methanol,alkylhalides, esters, ethers, aldehydes, ketones, amines, andthiocyanates. The catalyst of the invention can also be used in anytransalkylation process in which a polyalkylated organic compound isconverted into a lesser alkylated or nonalkylated organic compound bytransferring one or more alkyl groups from the polyalkylated compound toa similar compound containing fewer alkyl groups.

Although the catalyst of the invention can be used in anytransalkylation or alkylation process, its preferable uses are inprocesses for the alkylation of aromatic hydrocarbons with C₂ -C₄olefins to produce monoalkyl aromatic compounds and in thetransalkylation of aromatic compounds to produce monoalkyl aromaticcompounds. Normally, the alkylating agent used in such alkylationprocesses will be ethylene, propylene, isobutene or n-butene. Usually amonoalkylated product is desired, but polyalkylated products can also beproduced by, for instance, using toluene as the aromatic compound andethylene as the alkylating agent.

The catalyst of the invention is preferably used in alkylation andtransalkylation reactions to make cumene from benzene and propylene andto make ethylbenzene from benzene and ethylene. Cumene is commonly usedas an intermediate to produce phenol while ethylbenzene is primarilyused as an intermediate in producing styrene. FIG. 1 in the drawingillustrates a specific embodiment of the process of the invention inwhich the catalyst of the invention is utilized both as an alkylationand a transalkylation catalyst. This embodiment of the invention can beused to produce either cumene (isopropylbenzene) or ethylbenzenedepending on whether the alkylating agent utilized is propylene orethylene.

To start the process up, benzene is passed at ambient temperaturethrough lines 12 and 14, preheater 20 and line 22 into adiabaticalkylation reactor 24 which may contain one or more beds of the catalystof the invention. It is normally desired that the benzene introducedinto reactor 24 contain a small amount of water in order to maintaincatalyst stability during the alkylation process. Thus, the benzenenormally contains between about 20 and 3000 ppmw water, preferablybetween about 150 and 1500, and more preferably between about 300 and1000 ppmw water. The water-laden benzene is circulated at ambienttemperature through lines 26 and 28, heat exchanger 32, line 34,distillation column 36 and line 38 into lines 16 and 18. A portion ofthis benzene is recycled to reactor 24 through lines 14 and 22, whilethe remaining amount is passed through lines 18 and 54, preheater 56 andline 58 into transalkylation reactor 60 which also contains one or morebeds of the catalyst of the invention. From reactor 60, the benzene ispassed through lines 62 and 28, heat exchanger 32, and line 34 todistillation column 36.

Once the water-containing benzene is circulating at ambient temperaturethrough the process system as described above, the temperature of thebenzene is slowly increased toward alkylation and transalkylationtemperatures by use of preheaters 20 and 56, respectively. The catalystsin both reactors 24 and 60 contain a sufficient amount of water tomoderate their cracking activity with respect to benzene as thetemperatures in the reactors are raised to reaction levels. Thus,excessive cracking of the benzene into products that react with benzeneand condense to form larger molecules which deposit on the catalysts,thereby decreasing their life, is avoided. The catalysts containsufficient amounts of water so that their water content is equal to orgreater than the equilibrium water content of the catalysts at anytemperature during the period of heat up, which temperature exceeds thatat which the benzene begins to crack. Water levels in the catalysts ofabove 3.5 weight percent, preferably between 4.0 and 25 weight percent,are usually sufficient.

If the catalysts do not contain a sufficient amount of water when firstloaded into reactors 24 and 60, they can be hydrated in-situ prior toraising the beds to reaction temperature. This hydration can beaccomplished by passing humid air through the beds or contacting thebeds with the water-containing benzene at temperatures below whichbenzene cracks for a period of time sufficient for the catalyst toabsorb the required amount of water.

Once reactors 24 and 60 have been raised to operating temperatures whilecirculating hot benzene, ethylene or propylene, depending on the desiredproduct, is introduced into the system through line 10. The rate ofintroduction is slowly increased over a period of several days untildesign capacity is reached.

When the process is utilized to produce ethylbenzene, ethylene is passedthrough line 10 into line 14 where it is mixed with makeup benzeneintroduced into line 14 through line 12 and recycled benzene introducedinto line 14 through line 16. The resultant mixture of ethylene, makeupbenzene and recycled benzene is passed through line 14 into preheater 20and then through line 22 into alkylation reactor 24. In the upstreamportion of the catalyst bed in the alkylation reactor, ethylene reactswith benzene to produce ethylbenzene and polyalkylated aromaticcompounds such as di- and triethylbenzenes. In the downstream part ofthe reactor, these polyalkylated benzenes undergo transalkylation byreacting with benzene to form additional ethylbenzene. The temperaturein preheater 20 is controlled, depending upon the feed composition, toyield the desired maximum temperature in the alkylation reactor.Typically, the temperature in the alkylation reactor is between about200° F. and 900° F., preferably between about 300° F. and 600° F., andis sufficiently low that ammonium ions in the catalyst are notdecomposed and the formation of xylene is minimized. The pressureutilized in the reactor ranges between about 150 p.s.i.g. and 2000p.s.i.g., preferably between about 300 p.s.i.g. and 1500 p.s.i.g. Theweight hourly space velocity typically ranges between about 2 and 2000reciprocal hours, preferably between about 4 and 100 reciprocal hours.The mole ratio of benzene to ethylene used typically ranges betweenabout 1.0 and 100, preferably between about 4 and 40. The conditions oftemperature and pressure are preferably correlated so that a liquidphase is present in the reactor. An excess of benzene is utilized inorder to minimize the formation of oligomers and polymers of thealkylating agent, and undesired polyalkylated and other unwantedcompounds.

The effluent from reactor 24 contains, among other compounds,ethylbenzene, unreacted benzene, diethylbenzene, triethylbenzene,n-propylbenzene, ethylbenzene and other aromatic compounds. This mixtureis withdrawn from alkylation reactor 24 through line 26, depressured,and passed into line 28 where it is mixed with a recycle streamcontaining ethylbenzene which is introduced into line 28 through line62. The mixture in line 28 is then passed into heat exchanger 32 wherethe mixture is cooled to distillation temperature. The cooled mixture isthen passed through line 34 into distillation column 36 where unreactedbenzene is taken overhead via line 38 and recycled in part to alkylationreactor 24 via lines 16, 14 and 22. Water is removed from the top ofcolumn 36 to prevent its build up in the process flow system.

The bottoms product from distillation column 36, which comprisesethylbenzene, diethylbenzene and other benzene-derived impurities, ispassed through line 40 to distillation column 42 from which the desiredproduct ethylbenzene is recovered overhead through line 44. The bottomsproduct from column 42 is passed through line 46 into distillationcolumn 48 wherein diethylbenzene is removed overhead through line 50while a bottoms fraction comprising high boiling undesirable by-productsis removed from the distillation column through line 52 to prevent buildup of such compounds in the system.

The overhead stream from distillation column 48 is passed through line50, mixed with benzene withdrawn overhead of distillation column 36through lines 38 and 18, and passed through line 54 into preheater 56and then through line 58 into transalkylation reactor 60. Here, themixture of diethylbenzene and benzene is passed over the catalyst of theinvention under conditions such that transalkylation occurs, i.e., ethylgroups are transferred from the diethylbenzene to the benzene to formadditional ethylbenzene, which is the desired product from thisembodiment of the invention. The transalkylation reactor is normallyoperated at a temperature between about 350° F. and about 650° F.,preferably between about 400° F. to about 600° F., such that at leastsome of the reactants are present in the liquid phase. The pressure inthe transalkylation reactor typically ranges between about 150 p.s.i.g.and about 2000 p.s.i.g., preferably between about 300 p.s.i.g. and 1500p.s.i.g. The weight hourly space velocity normally ranges from about 0.5to 50 reciprocal hours, preferably between about 1 and 15 reciprocalhours. The mole ratio of benzene to diethylbenzene introduced into thereactor is generally between about 1 and about 50, preferably betweenabout 5 and about 40.

The effluent from transalkylation reactor 60 is withdrawn through line62 and passed to line 28 where it is mixed with the bottoms fromalkylation reactor 24 and subsequently passed through distillationcolumn 36 to distillation column 42 for recovery of the additionalethylbenzene produced in the transalkylation reactor.

It will be understood that the flow scheme set forth in FIG. 1 can beused to produce cumene as a desired product by substituting propylenefor the ethylene introduced into the process through line 10. When thisis done and conditions in the process units are adjusted appropriately,cumene instead of ethylbenzene is recovered overhead of distillationcolumn 42 through line 44 and diisopropylbenzene and triisopropylbenzeneare passed through lines 54 and 58 into transalkylation reactor 60 wherethey are converted via reaction with benzene into additional cumeneproduct.

In the process flow scheme shown in FIG. 1 and described above,reactants are passed downwardly through a single alkylation reactor 24,which is depicted as containing three beds of the catalyst of theinvention, and through a single transalkylation reactor 60, which isshown as containing only one bed of the catalyst of the invention. Itwill be understood that alternative embodiments of the invention includepassing the reactants upwardly through both reactors, using more beds ineach reactor or fewer beds in the alkylation reactor, employing morethan one reactor vessel for either alkylation or transalkylation, andusing a transalkylation catalyst other than the catalyst of theinvention in reactor 60. For example, in one embodiment of the inventionfor making ethylbenzene, benzene and ethylene are passed upwardlythrough two alkylation reactors containing two beds of the catalyst ofthe invention while benzene and diethylbenzene are passed upwardlythrough a single transalkylation reactor containing three separate bedsof the catalyst of the invention or another transalkylation catalyst.Although the process flow scheme depicted in FIG. 1 shows ethylene beingintroduced into the system in one location upstream of preheater 20, itwill be understood that the ethylene can be injected between preheater20 and alkylation reactor 24 and, in addition, between the beds ofcatalyst in reactor 24.

The nature and objects of the invention are further illustrated by thefollowing examples which are provided for illustrative purposes only andnot to limit the invention as defined by the claims. Example 1demonstrates that a hydrated catalyst of the invention has significantlyless cracking activity for benzene than an unhydrated catalyst. Example2 shows that a hydrated catalyst of the invention has a substantiallyincreased life when used to alkylate benzene with ethylene.

EXAMPLE 1

A catalyst was prepared by mulling a mixture of (1) LZY-82 zeolite, athe steam-stabilized, modified Y zeolite, and (2) Catapal alumina thathad been peptized with nitric acid. The mulled mixture was extrudedthrough a clover leaf-shaped die, dried and calcined in air. Thefinished catalyst contained about 90 weight percent LZY-82 zeolite,about 10 weight percent alumina and about 4,000 ppmw ammonium ions,calculated as (NH₄)₂ O on a voltiles-free basis. The water content ofthe catalyst was measured by placing a sample of the catalyst in amuffle furnace and heating it at a 1,000° C. for two hours. Afterheating, the sample was again weighed. The difference in weightsrepresents the loss on ignition (LOI) or the amount of volatiles presentin the catalyst. Since the catalyst contained some ammonium ions whichdecomposed into ammonia when the catalyst was heated, the LOImeasurement was adjusted to obtain the water content by subtracting theamount of ammonia generated. The water content calculated in this mannerwas about 3 weight percent based on the total weight of the catalyst. Aportion of this catalyst was hydrated by spreading a single layer on acoarse screen supported above a table in a vent hood while air wasfreely circulated around the catalyst for at least two hours to ensurecomplete hydration. The dry and hydrated catalysts were stored in sealedbottles until used. The water content of the hydrated catalyst asmeasured by LOI and corrected for ammonium ion content was approximately21 weight percent.

A 10 gram (dry basis) sample of the relatively dry catalyst, i.e., thecatalyst containing 3 weight percent water, was supported on quartzchips in a fixed bed bench scale reactor having an inside diameter of0.52 inches, which reactor was then placed in an electrically heatedtube furnace. Reagent grade benzene that had been dried to contain 50ppmw water was then passed downwardly through the reactor at a rate of30 ml per hour and at a pressure of 600 p.s.i.g. No ethylene wasintroduced into the reactor. A thin travelling thermocouple in anexternal thermowell running the length of the reactor was used tomeasure temperatures. The temperature in the tube furnance was raisedover a period of time to 480° F. The weight hourly space velocity was2.7 reciprocal hours. Effluent from the reactor was collected at 12 hourintervals over a 4-day period. The samples collected were then inspectedfor color. All samples had approximately the same level of intenseorange coloring. The orange product was analyzed by GC-MS methods andfound to contain, in addition to benzene, cumene, alkylated benzenes,phenylnaphthalene, perylene, and 4-and 5-membered condensed aromaticcompounds, i.e., polynuclear aromatics. These impurities were evidentlyformed by the reaction of benzene cracking products with one another,i.e., condensation, and with benzene.

The above-discussed experiment was repeated under identical conditionsexcept that 10 grams (dry basis) of the hydrated catalyst were used inlieu of the dry catalyst and the product was collected at 12 hourintervals for a period of 12 days. The samples of the benzene exitingthe reactor were then inspected, and all were found to have a lightyellow coloration indicating the presence of substantially fewerimpurities. It was thus concluded that much less benzene cracking hadoccurred over the hydrated catalyst than over the dry catalyst.

EXAMPLE 2

The conclusions drawn from the results of Example 1 were confirmed in apilot plant run in which the performance of the hydrated catalyst ofExample 1 for alkylating benzene with ethylene was compared to that ofthe dry catalyst. Twenty-five grams (dry basis) of the catalyst ofExample 1 containing 3 weight percent water were supported on quartzchips in a reactor which had an inside diameter of 0.68 inches and wassurrounded by a constant temperature bath of fine sand fluidized withair. Reagent grade benzene, to which water was added so it containedbetween 2,000 and 3,000 ppmw water, was passed upwardly through thereactor at 600 p.s.i.g. and a rate of 243 grams per hour by means of apiston pump. The fluidized sand bath was then raised in temperature tobetween 450° and 467° F. at which time polymer grade ethylene was mixedwith the benzene and passed upwardly through the fixed bed reactor at arate of 7.3 grams per hour. The weight hourly space velocity was 10reciprocal hours. The position of the reaction zone in the bed wasdetermined by measuring temperatures at intervals as small as 1/8 inchthrough the bed using a thin travelling thermocouple in a centralthermowell running the length of the reactor. Since the alkylationreaction is very exothermic and rapid, the temperature of the catalystbed rises steeply at the inlet of the reactor and then drops off as heatis lost through the reactor walls to the constant temperature bath. Themeasured peak temperature of between 472° and 486° F. was used to markthe position of the reaction zone in the bed. Every day the position ofthe peak temperature was determined using the thermocouple and wasplotted against time. These data are shown in FIG. 2.

As can be seen by the data in the figure, the position of the peaktemperature in the bed changed rather rapidly over the first 15 days.The slope of the line represented by the data points is the rate of peaktemperature travel, which rate is indicative of the length of thecatalyst bed deactivated per day. After about 33 days, a steady statewas reached where the rate of peak temperature travel remained fairlyconstant. About 57 percent of the catalyst bed was consumed when steadystate was reached. The life of the catalyst can be predicted by dividingthe length of the active catalyst bed remaining, i.e., 43 percent, bythe rate of peak temperature travel and adding the time required toreach steady state, i.e. 33 days.

The above described pilot plan run was repeated using 25 grams (drybasis) of the hydrated catalyst, i.e., the catalyst containing about 21weight percent water. All variables remained the same except that thebenzene use contained only 800 ppmw water instead of between 2,000 and3,000 ppmw. Again, the position of the peak temperature was measureddaily and the results are shown in FIG. 2. As can be seen, the rate ofpeak temperature travel reached a steady state after about 13 days andonly about 18 percent of the catalyst bed was consumed as compared to 57percent after 33 days for the dry catalyst. Since the peak temperaturemoved through both beds at about the same rate after steady state wasreached, which rate was very small, the predicted life of the hydratedcatalyst, i.e., the length of active catalyst bed remaining divided bythe rate of peak temperature travel plus the time to reach steady state,was about twice that of the dry catalyst. Such an increase in catalystlife has potentially large effects on the economics of the process sinceit allows the use of smaller amounts of reactants and less catalyst,which substantially cuts capital costs, and also results in the need forregenerating the catalyst fewer times during its total life time, whichsaves considerably on operation costs.

Although this invention has been primarily described in conjunction withthe examples and by reference to embodiments thereof, it is evident thatmany alternatives, modifications and variations will be apparent tothose skilled in the art in light of the foregoing description.Accordingly, it is intended to embrace within the invention all suchalternatives, modifications and variations that fall within the spiritand scope of the appended claims.

We claim:
 1. A process for producing an alkylated organic compound viaalkylation and/or transalkylation which comprises contacting an organicfeedstock with an organic reactant in the presence of a catalyst underconditions such that components of said organic feedstock react withsaid organic reactant to form said alkylated compound, wherein saidcatalyst is devoid of hydrogenation metal components and comprises acrystalline zeolitic molecular sieve having alkylation and/ortransalkylation activity, an inorganic refractory oxide component, andgreater than 3.5 weight percent water based on the total weight of saidcatalyst.
 2. A process as defined by claim 1 wherein said alkylatedorganic compound is produced via alkylation, said organic feedstockcomprises an aromatic compound and said organic reactant comprises anolefin.
 3. A process as defined by claim 2 wherein said alkylatedorganic compound comprises cumene, said aromatic compound comprisesbenzene and said olefin comprises propylene.
 4. A process as defined byclaim 2 wherein said alkylated organic compound comprises ethylbenzene,said aromatic compound comprises benzene and said olefin comprisesethylene.
 5. A process as defined by claim 2 wherein said aromaticcompound comprises benzene.
 6. A process as defined by claim 5 whereinsaid alkylating agent comprises a C₂ -C₂₅ olefin.
 7. A process asdefined by claim 6 wherein said alkylating agent comprises ethylene orpropylene.
 8. A process as defined by claim 4 wherein said zeoliticmolecular sieve is a steam-stabilized Y zeolite, said catalyst containsbetween about 4.0 and 25 weight percent water based on the total weightof said catalyst, and said inorganic refractory oxide component isalumina.
 9. A process as defined by claim 1 wherein said alkylatedorganic compound is produced via transalkylation, said organic feedstockcomprises an aromatic compound and said organic reactant comprises atransalkylating agent.
 10. A process as defined by claim 9 wherein saidalkylated organic compound comprises cumene, said aromatic compoundcomprises benzene and said transalkylating agent comprisesdiisopropylbenzene.
 11. A process as defined by claim 9 wherein saidalkylated organic compound comprises ethylbenzene, said aromaticcompound comprises benzene and said transalkylating agent comprisesdiethylbenzene.
 12. A process as defined by claim 16 wherein saidzeolitic molecular sieve is a steam-stabilized Y zeolite, said inorganicrefractory oxide component is alumina, and said catalyst containsbetween about 4.0 and 25 weight percent water based on the total weightof said catalyst.
 13. A process as defined by claim 1 wherein saidzeolitic molecular sieve is a zeolite.
 14. A process as defined by claim13 wherein said Y zeolite is selected from the group consisting ofdealuminated Y zeolites, ultrahydrophobic Y zeolites, andsteam-stabilized Y zeolites.
 15. A process as defined by claim 1 whereinsaid zeolitic molecular sieve is LZY-82 zeolite or LZY-84 zeolite.
 16. Aprocess as defined by claim 1 wherein said zeolitic molecular sieve isselected from the group consisting of zeolite Beta, zeolite L, zeoliteOmega, mordenite, Y zeolites, and X zeolites.
 17. A process as definedby claim 13 wherein said Y zeolite has an overall silica-to-alumina moleratio between about 3.0 and about 6.0.
 18. A process as defined by claim13 wherein said Y zeolite has an overall silica-to-alumina mole ratiobetween about 5.0 and about 6.0.
 19. A process as defined by claim 1wherein said catalyst contains between about 5.0 and about 15 weightpercent water based on the total weight of said catalyst.
 20. A processas defined by claim 1 wherein said catalyst contains between 5.0 and 10weight percent water based on the total weight of said catalyst.
 21. Aprocess as defined by claim 6 wherein said catalyst contains between 4.5and 9.5 weight percent water based on the total weight of said catalyst.22. A process as defined by claim 2 wherein said catalyst containsbetween 5 and 15 weight percent water based on the total weight of thesaid catalyst.
 23. A process as defined by claim 9 wherein said catalystcontains between 5 and 15 weight percent water based on the total weightof said catalyst.
 24. A process for producing ethylbenzene whichcomprises reacting benzene with ethylene in the presence of a catalystdevoid of hydrogenation components, said catalyst comprising a zeoliticmolecular sieve, an inorganic refractory oxide component, and betweenabout 4.0 and about 25 weight percent water based on the total weight ofsaid catalyst.
 25. A process as defined by claim 24 wherein said Yzeolite has an overall silica-to-alumina mole ratio between about 3.0and about 6.0.
 26. A process as defined by claim 24 wherein saidzeolitic molecular sieve is a Y zeolite.
 27. A process as defined byclaim 24 wherein said Y zeolite is selected from the group consisting ofdealuminated Y zeolites, ultrahydrophobic Y zeolites, andstream-stabilized Y zeolites.
 28. A process as defined by claim 24wherein said zeolitic molecular sieve is selected from the groupconsisting of zeolite Beta, zeolite L, zeolite Omega, mordenite, Yzeolites and X zeolites.
 29. A process as defined by claim 24 whereinsaid catalyst contains between about 5.0 and about 15 weight percentwater based on the total weight of said catalyst.
 30. A process asdefined by claim 24 wherein said catalyst contains between 4.5 and 9.5weight percent water based on the total weight of said catalyst.
 31. Aprocess as defined by claim 24 wherein said inorganic refractory oxidecomponent comprises alumina.
 32. A process for producing cumene whichcomprises reacting benzene with propylene in the presence of a catalystdevoid of hydrogenation components, said catalyst comprising a zeoliticmolecular sieve, an inorganic refractory oxide component, and betweenabout 4.0 and about 25 weight percent water based on the total weight ofsaid catalyst.
 33. A process as defined by claim 32 wherein saidzeolitic molecular sieve is a Y zeolite.
 34. A process as defined byclaim 33 wherein said Y zeolite is selected from the group consisting ofdealuminated Y zeolites, ultrahydrophobic Y zeolites, andsteam-stabilized Y zeolites.
 35. A process as defined by claim 32wherein said zeolitic molecular sieve is selected from the groupconsisting of zeolite Beta, zeolite L, zeolite Omega, mordenite, Yzeolites, and X zeolites.
 36. A process as defined by claim 33 whereinsaid Y zeolite has an overall silica-to-alumina mole ratio between about3.0 and about 6.0.
 37. A process as defined by claim 32 wherein saidcatalyst contains between about 5.0 and about 15 weight percent waterbased on the total weight of said catalyst.
 38. A process as defined byclaim 32 wherein said catalyst contains between 4.5 and 9.5 weightpercent water based on the total weight of the catalyst.
 39. A processas defined by claim 32 wherein said inorganic refractory oxide componentcomprises alumina.
 40. A process for producing an alkylated organiccompound via alkylation and/or transalkylation which comprisescontacting an organic feedstock with an organic reactant in the presenceof a catalyst under conditions such that components of said organicfeedstock react with said organic reactant to form said alkylatedcompound, wherein said catalyst is devoid of hydrogenation metalcomponents and comprises (1) greater than 3.5 weight percent water basedon the total weight of said catalyst, (2) a nonzeolitic molecular sieveselected from the group consisting of silicoaluminophosphates,metalloaluminophosphates, titanium silicates, galliosilicates,ferrosilicates, chromosilicates, borosilicates, pillared clays, anddelaminated clays, and (3) an inorganic refractory oxide component.